What Is Exhaust Gas Power Generation?
Many industrial processes generate exhaust gases or off-gas streams that contain combustible components, often treated as waste or vented. An exhaust-gas generator harnesses this wasted energy: after pretreatment (filtration, moisture removal, tar/particulate removal), the gas is mixed with air and combusted in a specially adapted lean-burn engine. The mechanical energy is converted into electricity — effectively transforming waste gas into usable power, reducing fuel costs and lowering emissions.
Common Sources of Suitable Exhaust Gas
Blast furnaces, smelting furnaces, metallurgical furnaces (steel, ferroalloy, non-ferrous metals)
Coke ovens and coking plants
Cement, lime, or brick kilns
Chemical plants, refineries, petrochemical off-gas streams
Gasification syngas exhaust
Industrial waste-gas recycling / emission-control systems
Introduction to Technical Features
Turbocharging and shunt Intake technology：
Avoiding the generation of mixed gas, the gas and air enters the cylinder isolated with no contact. At the same time, the exhaust enery from the generator will be used for turbocharing the gas and air respectively. It realizes the improvement of intake and the synchronous improvement of operation power and volume power and ensures safety operation at the same time.
From 2018 till now, the safe stayale running time is more than 30000 hours. The measured electric efficiency is more than 40% in practice - 1m3 exhaust gas generates one kilowatt-hour of electricity.
There is no carbon monoxide leakage, no backfire and flash explosion, and the genset runs smoothly. Self consumption rate is less than 2%. The operation control of the genset is automatically adjusted with the change of gas.
Technical parameters
| Model | CP22 | CP21 | CP11 | CP14 |
| CP1200GFJ22 | CP900GFJ21 | CP700GFJ11 | CP600GFJ11 | CP500GFJ11 | CP250GFJ14 | CP200GFJ14 |
| Electrical Output(kw) | 1200 | 900 | 700 | 600 | 500 | 250 | 200 |
| Electrical Efficiency(%) | 40 | 38 | 38 | 36 | 36 | 35 | 34 |
| Thermal Efficiency(%) | 44 | 45 | 45 | 44 | 43 | 44 | 43 |
| Total Efficiency(%) | 84 | 83 | 83 | 80 | 79 | 79 | 77 |
| Cylinder Number | 16 | 12 | 12 | 12 | 12 | 6 | 6 |
| Discharge(L) | 104.34 | 78.25 | 71.45 | 71.45 | 71.45 | 35.7 | 35.7 |
| Speed(r/min) | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 | 1000 | 1200 |
| Frequency(Hz) | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 | 50 | 60 |
| Length(mm) | 7409 | 6400 | 6300 | 6300 | 6300 | 4500 | 4500 |
| Width(mm) | 1822 | 1950 | 1950 | 1950 | 1950 | 1300 | 1300 |
| Height(mm) | 2325 | 2175 | 2175 | 2175 | 2175 | 2365 | 2365 |
| Weight(kg) | 19000 | 15000 | 14000 | 13500 | 13500 | 8400 | 7000 |
900 kW Generator — Technical Highlights & Advantages
High Electrical Efficiency: Up to ≈ 40% – 42% under optimal conditions, depending on gas quality and pretreatment.
Wide Gas Compatibility: Handles a broad range of waste gases — from low-calorific kiln gas to CO/H₂-rich furnace off-gases; designed to tolerate fluctuations in gas composition and calorific value.
Robust Engine Design: Heavy-duty cylinders, corrosion-resistant components, and reinforced ignition/control system for industrial gas conditions.
Turbocharging & Adaptive Gas-Air Mixing: Ensures stable combustion, even with inconsistent gas supply, avoiding misfire or knock — critical for exhaust-gas applications.
Continuous Heavy-Load Capability: Built for 24/7 operation under rated load, ideal for large-scale industrial plants demanding uninterrupted power supply.
Optional CHP & Heat Recovery: Waste heat from exhaust or engine cooling can be reclaimed for hot water or steam, improving overall energy utilization and plant efficiency.
Scalable & Modular: Suitable for standalone installation or multi-unit parallel operation to meet larger demand or redundancy requirements.
Lower Operational and Fuel Costs: Uses local exhaust gas instead of purchased fuel — savings on fuel purchase, waste-gas treatment, emissions fees, and disposal costs.
Environmental Compliance & Emission Reduction: Converts waste gas that might otherwise be flared or emitted — reducing greenhouse gas emissions and helping meet regulatory requirements.
Technical & Operational Data (900 kW)
| Parameter | Specification / Notes |
|---|
| Rated Electrical Output | 900 kW |
| Engine Type | Lean-burn gas engine adapted for waste gas combustion |
| Fuel / Gas Source | Industrial exhaust / flue / process gas (CO, H₂, CH₄, mixed gas) |
| Electrical Efficiency | ≈ 40% (varies by gas quality & pretreatment) |
| Total Efficiency (with heat recovery) | Up to ≈ 80–85% |
| Gas Supply Pressure Range | Low to medium (after pretreatment & pressure regulation) |
| Combustion Control | Adaptive ECU with gas composition monitoring & knock protection |
| Operation Mode | Continuous rated-load operation; base-load or backup configurations available |
| Optional Modules | Heat recovery (steam / hot water), remote monitoring, synchronization for multi-unit operation, sound-proof enclosure, grid-connection kit |
Gas Pretreatment & Safety Recommendations
For stable and safe operation, it is strongly recommended to install a comprehensive pretreatment system before the gas enters the generator:
Dust / particulate filters
Tar / VOC removal (if tar or hydrocarbons present)
Moisture separators / condensate traps
Gas desulfurization (H₂S removal) if sulfurous gases are present
Pressure regulation and safety valves
Flame arrestors and automatic shutdown safeguards
Typical Industrial Applications
Steel mills & metallurgical plants — utilizing furnace off-gas for onsite power and heating
Coke oven and coking plants — converting oven gas into electricity and steam
Cement, lime, and kiln industries — recovering kiln flue gas energy to reduce fossil fuel dependence
Chemical, petrochemical, and refinery off-gas recovery — tapping synthesis gas or process gas for power
Waste-to-energy and emission-recycling facilities — turning industrial emissions into usable power
Distributed industrial power stations & cogeneration (CHP) plants — supplying electricity + steam/hot water for plant operations
Economic & Environmental Benefits
Adopting the 900 kW exhaust-gas generator brings substantial long-term value:
Significantly reduced fuel expenditure — waste gas becomes fuel, fuel purchase costs drop sharply.
Lower emissions and compliance costs — fewer flared gases, reduced greenhouse gas emissions, improved environmental footprint.
Improved energy utilization efficiency — with optional heat recovery, total energy usage (electricity + heat) reaches 80–85%.
Reduced waste disposal cost — less need for flue gas treatment or venting systems, or avoiding fines / penalties for emissions.
Enhanced sustainability profile — aligns with green manufacturing and ESG / corporate responsibility goals.
Reliable on-site power supply — reduces dependence on external fuel supply or grid stability, especially for remote or heavy-load industrial sites.
Operation & Maintenance Guidelines
Perform gas pretreatment system maintenance regularly (filters, moisture traps, tar scrubbers).
Check engine ignition system, valves, spark timing, and knock detection periodically if gas composition frequently changes.
Inspect exhaust and safety systems (flame arrestors, pressure relief valves) to ensure safe operation.
If equipped with heat recovery, maintain heat exchanger, condensate management, and water/steam circuit to prevent scaling or corrosion.
For multi-unit installations, schedule regular synchronization checks and load-sharing tests.
Frequently Asked Questions (FAQ)
Q: What kinds of exhaust or waste gases can the 900 kW generator use?
A: It accepts a wide range of gases containing combustible components — including furnace off-gas, kiln flue gas, synthesis gas, CO / H₂-rich gases, mixed industrial waste gases — provided that proper pretreatment (dust, tar, moisture, H₂S removal) is applied.
Q: What is the minimum required calorific value for stable operation?
A: Typically ≥ 1.5 MJ/Nm³ after pretreatment, but stable operation thresholds may vary with gas composition, pressure, and pretreatment quality.
Q: Can the unit run continuously 24/7 under rated load?
A: Yes. The engine and genset are engineered for continuous heavy-load operation with high reliability and durability.
Q: Does the system support combined heat & power (CHP)?
A: Yes. When equipped with a heat recovery module, exhaust heat or cooling system heat can be used to generate hot water or steam — improving total energy efficiency up to 80–85%.
Q: Can multiple 900 kW units operate in parallel for higher capacity?
A: Yes. The system supports multi-unit parallel operation with synchronization control, allowing flexible scaling per demand.
Get a Customized Waste-Gas Power Solution
We provide complete exhaust-gas power generation solutions — from gas analysis and pretreatment, to generation set supply, heat recovery, installation, commissioning, and after-sales service.
Contact us today to design a turnkey 900 kW exhaust-gas generator solution tailored to your industrial gas composition, load requirements, and site conditions.
